Pressure-sensitive label

ABSTRACT

A pressure sensitive label and method for preparing same, the pressure sensitive label comprising: (a) a support portion, the support portion including at least a carrier layer; and (b) a transfer portion over the support portion for transfer of the transfer portion from the support portion to an article upon application of pressure to the transfer portion while the transfer portion is in contact with the article, the transfer portion including at least a printable layer in confronting relationship with the carrier layer, and an ink layer positioned between the printable layer and carrier layer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 14/724,021, entitled “Pressure-Sensitive Label,” filed May 28,2015, the disclosure of which is incorporated by reference herein in itsentirety.

FIELD OF THE INVENTION

The present invention relates generally to labels for various articles,and relates more specifically to pressure sensitive labels for articles,such as containers.

BACKGROUND OF THE INVENTION

This section is intended to introduce the reader to various aspects ofart that may be related to various aspects of the present invention,which are described and/or claimed below. This discussion is believed tobe helpful in providing the reader with background information tofacilitate a better understanding of various aspects of the presentinvention. Accordingly, it should be understood that these statementsare to be read in this light, and not as admissions of prior art.

Pressure sensitive labels are multi-layered constructions that include apressure-sensitive adhesive, and are used to label articles by applyingpressure to the label when it is in contact with an article to adherethe label to the article via the pressure-sensitive adhesive. Suchpressure sensitive labels are popular because, among othercharacteristics, they are versatile, and allow for a high level ofprintability with bright colors printed on surfaces. Further, they canbe printed onto a large spectrum of materials such as paper, foil,metal, plastic, and other synthetic materials. They are also compatiblewith a wide array of finishing processes, including (but not limited to)perforating, embossing, and hot stamping.

Referring to FIG. 1, a typical prior art pressure sensitive label 1 isshown. When labeling an article with a pressure sensitive label, onegenerally acquires a base pressure sensitive label stock 2 from aseparate supplier. The base pressure sensitive label stock 2 usuallyincludes at least four laminated layers: (1) a carrier 3 (sometimesreferred to as a “liner”), (2) a release layer 4 disposed onto onesurface of the carrier, (3) an adhesive layer 5 (including apressure-sensitive adhesive) disposed onto the release layer, and (4) aface stock 6 disposed onto the adhesive layer.

The typical base pressure sensitive label stock 2 can thus be thought ofas having a support portion 7 (carrier 3 and release layer 4) and atransfer portion 8 (adhesive 5 and face stock 6). The release layer 4 isused to allow the portion that will transfer to an article to peel awayand release from the carrier 3 during label application.

The face stock 6 is typically made from a web or sheet of paper, film,or foil, and is applied or laminated to the adhesive layer 5sequentially at some time after the adhesive layer 5 has been laid down.Once the base pressure sensitive label stock 2 is acquired from asupplier, the face stock 6 may then be printed on with an ink layer 9 orlayers (text, graphics, indicia, etc.) to create the label decorationand information. The conventional pressure sensitive label constructionis then applied to an article surface by removing the carrier 3 andrelease layer 4 to expose the adhesive layer 5 and placing the adhesivelayer 5 into contact with the desired surface and applying pressure, totransfer the adhesive 5, face stock 6, and ink layer 9 to the article(the “ink layer” as described herein may include more than one ink tocreate the appearance of the label decoration and information).

While these pressure sensitive labels are well known, there are manydrawbacks to the use of the above-described pressure-sensitive labels.As described above, the initial base pressure sensitive label stock(carrier, release layer, adhesive layer, and face stock) is generallyprovided by a third party with the label design (i.e., ink graphics,text, indicia, etc) being added thereafter. This does not allow for theconstruction of an entire label (e.g., carrier, release layer, adhesivelayer, face stock, and ink layer) at one location and/or time. And so,present pressure sensitive labels require a multi-location, multi-stepprocess for their production, thereby lengthening the amount of timeneeded to manufacture a completed pressure sensitive label. (When the“construction of a label,” or the like, is referenced herein, it isintended to refer to both the construction of an individual label and/orto the construction of a web of multiple individual labels.)

Further, the supplier of the base pressure sensitive label stock doesnot know ahead of time what size shape, contour, etc. of ink layerindicia will be printed on the base stock to create the final web oflabels (the “web of labels” being a length of base pressure sensitivelabel stock with multiple individual labels printed via ink/indiciaalong its length). Thus, the base pressure sensitive label stock iscreated with a flood coating of adhesive and a face stock that matchesor generally closely matches the area of the carrier (to accommodate anysize, shape, contour, etc. of ink layer or layers that may be printed,and any size, shape, and/or contour of label or labels). Because ofthis, following printing of the ink design, the web of labels must bedie cut to produce the final web (carrier/release with individually cutlabels thereon). This process requires that the carrier be made of astrong material—such as a polyester—so that it can withstand the die cutprocess without being cut itself (as only the ink layer, face stock,adhesive, and release gets cut). The cut matrix that does not includelabels is then removed and discarded. The use of the strong material(e.g., polyester) of the carrier presents the problem that the carriercannot be recycled, as the material cannot be placed into the recyclestream for label web materials. While the carrier is commonly polyester,that does not prevent the use of other materials for the carrier (suchas a paper liner, glassine, polypropylene, or blends of such materials).

Further, because the base pressure sensitive label stock needs to beprovided by a third party with printing of the ink layer occurringthereafter, it is required that the layers of the final label be orderedin such manner that the adhesive is proximal to the carrier (e.g.,adjacent to the release layer) with the ink disposed distal from thecarrier. This configuration results in further drawbacks to the pressuresensitive labels of the prior art. First, the fact that the adhesive isproximal to the carrier requires a release layer or coating between thecarrier and the adhesive to allow the adhesive, face stock, and inklayer to release from the carrier during application to an article. Theneed for this release layer adds materials, and thus cost, to theseconventional pressure sensitive labels. Second, the positioning of theink layer distal to the carrier means that the ink layer will be theouter surface of the label once it is applied to an article. This meansthat the ink layer can be easily scuffed or damaged—disrupting theaesthetic appearance of the article. This also means that metallicscannot be used as inks in these conventional pressure-sensitive labels(due to their ease of damage). Thus, the inks that can be used in theselabels are limited, and the designs are subject to damage. One could adda protective layer to the label (to the outside of the ink layer) but,like the release layer described above, this adds yet another layer, andcost, to the label.

Further, where the label is to be adhered to a contoured or irregularsurface, and where a high degree of flexibility is desired, the rigidityof the face stock (and any rigidity due to the multiple layers of thelabel) may interfere with the application and the adherence of thelabel.

Further still, one common occurrence in the application of a pressuresensitive label is to have various defects, such as wrinkles andblisters. These defects occur when the label becomes misaligned to thearticle to which it is applied, and/or entrapment of air between thelabel and the article. The result is less than optimum visual appeal(poor aesthetics), label failure due to scuffing or tearing of theunsupported label, or even unsellable products.

In view of many of the drawbacks of pressure sensitive labels, asdescribed above, (particularly the many layers that are needed, the useof a third party base construction, and the damage that can occur to thelabel indicia), many have often turned to heat transfer labels as analternative type label. Heat transfer labels are desirably resistant toabrasion and chemical effects in order to avoid a loss of labelinformation and desirably possess good characteristics of adhesion tothe articles to which they are affixed.

Heat transfer labels are multilayered constructions, with each layerhaving its own function. For example, heat transfer labels generallyinclude an adhesive layer, an ink layer, and a release layer. Therelease layer may be a wax release layer, and is often directly adjacenta carrier sheet, such as on a roll or web of labels. Thus, in such anexample, the label may be thought to include a “support portion” (e.g.,carrier sheet and release layer and a “transfer portion” (i.e., inklayer and adhesive layer). When subjected to heat, the wax release layermelts, thereby allowing the transfer portion to be separated from thecarrier sheet, and the adhesive layer adheres the ink layer to anarticle being labeled. Alternatively, all or part of the wax releaselayer may transfer as well, to provide protection to the ink layer.Additionally or alternatively, the labels may include a separateprotective layer overlying the ink layer to protect the ink layer fromabrasion.

More specifically, in the heat transfer labeling process, thelabel-carrying sheet is subjected to heat, and the label is pressed ontoan article with the ink layer making direct contact with the article. Asthe paper sheet is subjected to heat, the wax layer begins to melt sothat the paper sheet can be released from the ink layer. (And, asdescribed above, a portion of the wax layer may be transferred with theink layer and a portion of the wax layer may remain with the papersheet.) After transfer of the ink layer to the article, the paper sheetis removed, leaving the ink layer firmly affixed to the article. In analternate embodiment, where the wax layer also transfers, the wax layerthus may serve two purposes: (1) to provide release of the ink layerfrom the sheet upon application of heat to the sheet, and (2) to form aprotective layer over the transferred ink layer. After transfer of thelabel to the article, the transferred wax release layer may be subjectedto a postflaming technique which enhances the optical clarity of thelayer (thereby enabling the ink layer therebeneath to be betterobserved) and which enhances the protective properties of thetransferred wax layer.

However, the primary drawback to the use of the heat transfer label isthe requirement of heat to be applied during the labeling process, whichmay not be desirable. It is, therefore, desirable that a pressuresensitive label construction be constructed for use as a label, forexample, which avoids the need to use a conventional face stock formedfrom paper, film, or foil. It is further desirable that the pressuresensitive label construction have printability, convertibility anddispensability properties that are better than or equal to that ofpressure sensitive label constructions of the prior art (as describedabove). It is also desirable that such a pressure sensitive labelconstruction be designed in a manner that reduces the amount ofmanufacturing time needed to complete same, when compared to a pressuresensitive construction of the prior art. Further, it would be desirableto reduce and/or eliminate wrinkles and/or blisters that may form duringlabel application. Further, it would be desirable for such a pressuresensitive label construction to have reduced layers, and thus cost,increase recyclability, increase ease of application to an article beinglabeled, and reduce the incidence or likelihood of damage to the inklayer.

SUMMARY OF THE INVENTION

Certain exemplary aspects of the invention are set forth below. Itshould be understood that these aspects are presented merely to providethe reader with a brief summary of certain forms the invention mighttake and that these aspects are not intended to limit the scope of theinvention. Indeed, the invention may encompass a variety of aspects thatmay not be explicitly set forth below.

Various aspects of the present invention address any and/or all of thedrawbacks described above with pressure sensitive labels of the priorart by providing pressure sensitive labels that, among othercharacteristics, have reduced layers, reduced cost, increasedrecyclability, increased ease of application to an article beinglabeled, and reduced incidence or likelihood of damage to an ink layer(as compared to pressure sensitive labels of the prior art, as describedin the Background). To accomplish this, one aspect of the presentinvention provides a pressure sensitive label comprising: (a) a supportportion including at least a carrier layer; and (b) a transfer portionincluding at least a printable layer in contacting relationship with thecarrier layer. In general, the transfer portion may overlie the supportportion for transfer of the transfer portion from the support portion toan article upon application of pressure to the transfer portion whilethe transfer portion is in contact with the article. In one aspect ofthe present invention, the carrier layer does not include any releaselayer between the carrier layer and the printable layer. This eliminatesa layer of the labels of the prior art, thus reducing the cost of thelabel.

Further, in another aspect of the present invention, the printable layermay be applied in a softened, molten, thixotropic, liquid, etc. formthat allows it to be applied as a pattern (such as in the shape, size,contour, etc. of a label image—i.e., graphics, text, indicia, etc.—thatis to be produced) rather than being provided as a face stock thatmatches (or substantially matches) the area of the carrier layer (as inlabels of the prior art). The printable layer is of a formulation thatallows it to receive ink thereon following cooling, solidifying,UV-curing, etc. The ability to apply the printable layer in a patternalso reduces the amount of material that is needed for the web of labels(thereby reducing cost), eliminates the need for die cutting (and thewaste of the discarded die cut material), and can be used to allow theentire label to be constructed in one location (as opposed to the needof acquiring a base pressure sensitive label stock from a third partysupplier).

In other aspects, the label may include an ink layer positioned suchthat the printable layer is between the carrier layer and the ink layer.And, the label may include an adhesive layer positioned such that theink layer is between the printable layer and the adhesive layer. By thisconfiguration, the pressure sensitive labels described herein includethe printable layer most proximal to the carrier, and the adhesive layermost distal to the carrier (which is a somewhat opposite configurationas compared to the pressure sensitive labels of the prior art). Due tothis configuration, the transfer portion (e.g., printable layer, inklayer, adhesive layer) of the pressure sensitive labels described hereindo not have to be peeled away from the carrier to expose the adhesivefor adherence to an article. Rather, the labels are configured such thatthe adhesive is already the outer layer of the label construction priorto application to an article, and so the adhesive is pre-exposed andready to contact an article—thereby increasing the ease of applicationto an article.

The configuration of the layers in this aspect and embodiment of thepresent labels also results in the ink being beneath the printable layer(and thus protected by the printable layer) once the transfer portion istransferred to an article. This results in the ink layer (the indicia,graphics, design, text, information, etc.) being protected from damageonce the label is transferred to an article. This protection is achievedwithout have to add any additional protective lacquer layers (as is donesometimes with prior art pressure sensitive labels). The configurationthat allows the printable layer to protect the ink layer followingtransfer also increases the number of materials that may be used in theink layer —such as being able to use easily damaged materials, such asmetallic inks.

In another aspect, the pressure sensitive label may further include arelease layer positioned such that the carrier layer is between theprintable layer and the release layer. In other words, the release layeris not on the side of the carrier adjacent to the transfer portion ofthe label, but rather is on the underside or backside of the carrier.This release layer allows the web of labels to be wound on a roll, forexample, while preventing blocking (i.e., the problem of the adhesive onthe labels adhering to the underside of the carrier as the web of labelsis wound on the roll).

Another aspect of the present invention provides a pressure sensitivelabel comprising: (a) a support portion including at least a carrierlayer; and (b) a transfer portion including at least a printable layerin confronting relationship with the carrier layer, and an ink layer maybe present between the printable layer and the carrier layer. Dependingon the nature of the ink layer, at least a portion or portions of theprintable layer may contact the carrier layer (i.e., in any areas whereink or inks of the ink layer are not present). In general, the transferportion may overlie the support portion for transfer of the transferportion from the support portion to an article upon application ofpressure to the transfer portion while the transfer portion is incontact with the article. In one embodiment, the carrier layer does notinclude any release layer on the side of the carrier layer facing theink layer. This eliminates a layer of the labels of the prior art, thusreducing the cost of the label. In this configuration, the pressuresensitive labels of this aspect include the ink layer most proximal tothe carrier, and the adhesive layer most distal to the carrier. Due tothis configuration, the transfer portion (e.g., ink layer, printablelayer, adhesive layer) of the pressure sensitive labels described inthis aspect do not have to be peeled away from the carrier to expose theadhesive for adherence to an article. Rather, the labels are configuredsuch that the adhesive is already the outer layer of the labelconstruction prior to application to an article, and so the adhesive ispre-exposed and ready to contact an article —thereby increasing the easeof application to an article. Further, this version of the label mayalso include a release layer positioned such that the carrier layer isbetween the ink layer and the release layer (to prevent blocking whenthe web of labels is wound on a roll, for example).

Another aspect of the present invention may include a method or methodsfor making a pressure sensitive label. And another aspect of the presentinvention may include a method or methods for applying a pressuresensitive label to an article.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention and,together with the general description of the invention given above andthe detailed description of the embodiments given below, serve toexplain the principles of the present invention.

FIG. 1 is a cross-sectional view of a typical pressure sensitive labelconstruction of the prior art.

FIG. 2 is a cross-sectional view of one embodiment of a pressuresensitive label construction in accordance with principles of thepresent invention.

FIG. 2A is a cross-sectional view of another embodiment of a pressuresensitive label construction in accordance with principles of thepresent invention.

FIG. 3 is a cross-sectional view of another embodiment of a pressuresensitive label construction in accordance with principles of thepresent invention.

FIG. 3A is a cross-sectional view of yet another embodiment of apressure sensitive label construction in accordance with principles ofthe present invention.

FIG. 4 is a cross-sectional view of another embodiment of a pressuresensitive label construction in accordance with principles of thepresent invention.

FIG. 4A is a cross-sectional view of yet another embodiment of apressure sensitive label construction in accordance with principles ofthe present invention.

FIG. 5 is a schematic showing the preparation of a pressure sensitivelabel construction in accordance with principles of the presentinvention.

FIG. 6 is a schematic showing a completed pressure sensitive label inaccordance with principles of the present invention on a roll of labels.

FIG. 7 is a schematic showing application of a pressure sensitive labelconstruction in accordance with principles of the present invention toan article.

FIG. 8 depicts an article with a pressure sensitive label in accordancewith the principles of the present invention associated therewith.

DETAILED DESCRIPTION

One or more specific embodiments of the present invention will bedescribed below. In an effort to provide a concise description of theseembodiments, all features of an actual implementation may not bedescribed in the specification. It should be appreciated that in thedevelopment of any such actual implementation, as in any engineering ordesign project, numerous implementation-specific decisions must be madeto achieve the developers' specific goals, such as compliance withsystem-related and business-related constraints, which may vary from oneimplementation to another. Moreover, it should be appreciated that sucha development effort might be complex and time consuming, but wouldnevertheless be a routine undertaking of design, fabrication, andmanufacture for those of ordinary skill having the benefit of thisdisclosure.

As described above, various aspects of the present invention address thedrawbacks described above with pressure sensitive labels of the priorart by providing pressure sensitive labels that, among othercharacteristics, have reduced layers, reduced cost, increasedrecyclability, increased ease of application to an article beinglabeled, and reduced incidence or likelihood of damage to an ink layer(as compared to pressure sensitive labels of the prior art, as describedin the Background). To accomplish this, one aspect of the presentinvention provides a pressure sensitive label comprising: (a) a supportportion including at least a carrier layer; and (b) a transfer portionincluding at least a printable layer in contacting relationship with thecarrier layer. In general, the transfer portion may overlie the supportportion for transfer of the transfer portion from the support portion toan article upon application of pressure to the transfer portion whilethe transfer portion is in contact with the article. In one aspect ofthe present invention, the carrier layer does not include any releaselayer between the carrier layer and the printable layer. This eliminatesa layer of the labels of the prior art, thus reducing the cost of thelabel.

Referring now to FIG. 2, one embodiment of such a pressure sensitivelabel 10 is shown. As can be seen in FIG. 2, the pressure sensitivelabel 10 of the illustrated embodiment is a multilayered construction,with each layer having its own function. Other embodiments are also of amultilayered construction. In general, the labels include a “supportportion” 12 (e.g., a carrier layer 14) and a “transfer portion” 18(e.g., at least a printable layer 20—although various embodiments mayalso include an ink layer 22, and an adhesive layer 24, for example).When subjected to pressure, as will be described in greater detailbelow, the transfer portion 18 may be separated from the carrier 14 toadhere to an article. This occurs when the label 10 is placed inconfronting relationship with an article 26 and pressure is applied,such that the transfer portion 18 makes direct contact with an outersurface 28 of the article 26 (an article 26 can be seen in FIGS. 7 and8). After contact of the transfer portion 18 to the article 26, thecarrier sheet 14 is removed, leaving the transfer portion 18 affixed tothe article 26 via the adhesive layer 24 of the transfer portion 18.

There may be several embodiments of the pressure sensitive labels 10 inaccordance with aspects of the present invention. All embodimentsinclude the general support portion 12 and transfer portion 18 describedabove. The support portion 12 of each embodiment includes a carrierlayer 14, which may have a release coating 16 (e.g., a wax or siliconecoating) on one side thereof (which can be seen in the embodiment shownin FIG. 2A). In an alternate embodiment, the carrier 14 may have norelease coating, but may be otherwise treated, such as by a coronatreatment. In still other embodiments, the carrier 14 may be untreatedand have no release coating. The transfer portion 18 of each of theembodiments is positioned adjacent to, and in confronting relationshipwith, the carrier 14 prior to transfer therefrom. The transfer portion18 of the embodiments includes at least (1) a printable layer 20 inconfronting relationship with the carrier 14. Such a confrontingrelationship does not require contact between the two layers (althoughcontact is possible). The layers merely need be proximal and adjacentone another, though there may be one layer or coating between thecarrier 14 and the printable layer 20—e.g., as in FIG. 2A. The transferportion 18 may also include an ink layer 22, and an adhesive layer 24.In the embodiments shown in FIGS. 2 and 2A, the ink layer 22 may bepositioned such that the printable layer 20 is between the carrier layer14 and the ink layer 22. And, in those embodiments, the adhesive layer24 may be positioned such that the ink layer 22 is between the printablelayer 20 and the adhesive layer 24. Additional layers may be includedwithin the transfer portion 18.

Certain layers of the pressure sensitive label 10 may be made withUV-curable materials (and in some embodiments, all the layers mayinclude UV-curable materials). UV-curable materials are generally knownto those of ordinary skill in the art. For example, certain inks,coatings and adhesives are formulated with photoinitiators and resins.When exposed to the correct energy and irradiance in a certain band ofUV light, polymerization occurs, and so the material cures. Thisreaction may take only a few seconds. The UV sources used may include UVlamps and UV LEDs. Fast processes such as flexographic printing (whichmay be used for certain layers on certain embodiments of the pressuresensitive labels, or on all layers) may use high intensity light.

Referring still to FIG. 2, the illustrated embodiment includes a carrierlayer 14, a printable layer 20, an ink layer 22, a pressure sensitiveadhesive layer 24, and a backside release layer 27. As can be seen fromFIG. 2, the release layer 27 is positioned such that the carrier layer14 is between the printable layer 20 and the release layer 27. As willbe described in further detail below (in a more detailed discussion ofthe various layers of the labels 10), the backside release layer 27prevents blocking when the web of labels is wound on a roll, forexample.

As described above, the various pressure sensitive label embodiments inaccordance with principles of the present invention include a carrierlayer 14. The carrier layer 14 as used in certain embodiments (and inthe illustrated embodiment of FIG. 2) is of a material that allows thetransfer portion 18 of the label 10 to separate from the carrier layer14 without the need for a separate release layer (such as release layersin the prior art). This allows for the reduction in materials and costused in the present pressure sensitive labels. And so, in embodiments ofthe present invention, the carrier layer 14 is of, or includes, amaterial having a surface tension that allows the printable layer 20 toreleasably bond thereto. And, in more specific embodiments of thepresent invention, the surface of the carrier layer 14 that contacts theprintable layer 20 may have a dyne level below about 32.

Further, as described above, a web of the labels 10 may be wound on aroll (See, for example, FIG. 6). In the wound state, the adhesive layer24 of a label will contact the carrier portion 12 of the label web ontop of it (and may particularly contact the backside release layer 27).In such embodiments, the bond of transfer portion 18 to the carrier 12needs to be stronger than any bond between the adhesive layer 24 and therelease layer 27 (or back surface of carrier 14) of an adjacent portionof the wound web. This prevents the transfer portion 18 from prematurelyseparating from the support portion 12 during unwinding of the roll.

The carrier layer 14 of various embodiments of the present invention mayinclude various materials, so long as those materials allow for areleasable bond of the printable layer 20 thereto (as described above).For example, the carrier layer 14 may be chosen from materials such asplastic film, foil, parchment, lightweight paper, and heavyweight paper.In one specific exemplary embodiment, the carrier layer 14 may includepolypropylene. And, more specifically, in certain embodiments, thecarrier layer may be a biaxially-oriented co-extruded polypropylene filmhaving an oriented polypropylene core, a treatable polyolefin layer onthe underside of the core, and a corona treated polyolefin layer on thetopside of the core (i.e., the treatable polyolefin layer being the sidethat would confront and/or contact the printable layer—the treatablelayer including the surface that receives the printable layer when theprintable layer contacts the treatable layer). In one specificembodiment, the carrier layer may include Rayoface™ C 160 film,commercially available from Innovia Films, Inc. of Atlanta, Ga.

A second film is commercially available under the product nameTT—General Purpose Non Heatsealable BOPPfilm, from AmTopp of Livingston,N.J. This film is also a coextruded film with an oriented polypropylenecore, a treatable polypropylene layer on the underside of the laminate,and a high energy treated polypropylene layer on the top. Like theembodiment of film described above, the underside is the layer whichwill be printed.

Yet another film, in another embodiment of the present invention, iscommercially available under the product name Hostaphan® 447CRL ClearNon-Silicone Release Liner, from Mitsubishi Polyester Film of Greer,S.C. This film is chemically primed on one surface for adhesive releaseand a low coefficient of friction, and is chemically primed on theopposite surface for adhesion promotion.

In other embodiments (such as the illustrated embodiment of FIG. 2A),the carrier layer may have a coating 16 applied to the surface that willconfront the printable layer 20 of the label 10. Thus, the carrier layer14 has two surfaces: (1) a top surface 29, which has a surface tensionlow enough to allow the printable layer 20 to releasably bond to it(which can be accomplished, as described above, with various treatmentsof the top surface—such as with silicones and/or waxes in the embodimentof FIG. 2A); and (2) a bottom surface 31, which is treated (as will bedescribed in greater detail below) to prevent adhesives 24 from adheringto it—thereby allowing the finished web of labels to be wound into aroll (and subsequently unwound during the label application process)without damaging the labels by having the labels adhere to one anotherand to the web (i.e., blocking).

In the more specific embodiments of the carrier described above, thesurface of the carrier layer 14 that contacts the printable layer 20 mayhave a dyne level below about 32.

As described above, the pressure sensitive label 10 of the variousembodiments also includes a printable layer 20 that may be disposed ontoand may contact the carrier layer 14. This is different from pressuresensitive labels of the prior art (as shown in FIG. 1), which included apressure sensitive adhesive 5 against a release layer 4 on the carrierlayer 3. Referring again to FIGS. 2 and 2A, the printable layer 20 maybe a film layer positioned in confronting relationship with the carrierlayer, or it may be a material, such as a varnish, which can be printedonto the carrier layer, to thereafter solidify (or be solidified) to astate that allows the printing of an ink design (text, graphics, and allother indicia) thereon. By using a printable layer 20 that may beapplied in a softened, molten, thixotropic, liquid, etc. form, theprintable layer 20 may be applied as a pattern (such as in the shape,size, contour, etc. of a label that is to be produced) rather than beingprovided as a face stock that matches (or substantially matches) thearea of the carrier layer (as in labels of the prior art). The printablelayer 20 is of a formulation that allows it to receive ink thereonfollowing cooling, solidifying, UV-curing, etc. The ability to apply theprintable layer 20 in a pattern also reduces the amount of material thatis needed for the web of labels (thereby reducing cost), eliminates theneed for die cutting (and the waste of the discarded die cut material),and can be used to allow the entire label to be constructed in onelocation (as opposed to the need of acquiring a base pressure sensitivelabel stock from a third party supplier).

In certain embodiments, the printable layer 20 may include a materialformulated from a base resin. This base resin may, in variousembodiments, be chosen from vinyls, acrylics, urethanes, epoxys,polyesters, and alkyds. Further, the printable layer 20 issolvent-based, water-based, or ultraviolet curable-based. The printablelayer 20, including these solvent-based, water-based, and/or UVcurable-based chemistries, (which are formulated from the base resins),may be formulated into a printable liquid at the viscosity and rheologyapplicable to various printing processes (such as screen printing,ink-jet printing, flexographic printing, rotogravure printing, andlithographic printing for example). In one specific embodiment, theprintable layer may include an imprintable varnish including atriacrylate ester monomer, a diacrylate ester monomer, an aromaticurethane acrylate, a difunctional acrylate, an acrylate oligomer,triethanolamine, and 4-phenylbenzophenone. In a more specificembodiment, the printable layer may include an imprintable varnishincluding about 30 wt % to about 50 wt % of a triacrylate ester monomer,about 10 wt % to about 12.5 wt % of a diacrylate ester monomer, about 10wt % to about 12.5 wt % of an aromatic urethane acrylate, about 10 wt %to about 12.5 wt % of a difunctional acrylate, about 5 wt % to about 7wt % of an acrylate oligomer, about 3 wt % to about 5 wt % oftriethanolamine, and about 1 wt % to about 2 wt % of4-phenylbenzophenone Such an imprintable varnish may be supplied inliquid form, have a density of about 1.07 g/cm³ (about 8.92 lb/gal orabout 1070 g/l), have a flash point of greater than about 93° C., and aboiling point of about 106° C. One example of such an imprintablevarnish is commercially available from INX International Ink Co. ofSchaumburg, Illinois, under the product name ProcureTM KCC5185 (andproduct code 1487893). Another such print-receptive coating is JRX-1253,commercially available from Dyna-Tech Adhesives and Coatings, Inc., ofGrafton, West Virginia. JRX-1253 is a UV radiation cured printable andmetallizable coating for plastics such as PET, PE, etc. It is printablewith UV and classical solvent and water based inks. At 100% solids, itis clear after curing. Those of ordinary skill in the art will recognizethat other materials of the same or similar characteristics may be usedin embodiments of the present invention.

In other aspects, the label 10 may include an ink layer 22 positionedsuch that the printable layer 20 is between the carrier layer 14 and theink layer 22. And, the label 10 may include an adhesive layer 24positioned such that the ink layer 22 is between the printable layer 20and the adhesive layer 24. By this configuration, the pressure sensitivelabels 10 described herein include the printable layer 20 most proximalto the carrier 14, and the adhesive layer 24 most distal to the carrier14 (which is a somewhat opposite configuration as compared to thepressure sensitive labels of the prior art). Due to this configuration,the transfer portion 18 (e.g., printable layer 20, ink layer 22,adhesive layer 24) of the pressure sensitive labels described herein donot have to be peeled away from the carrier to expose the adhesive foradherence to an article. Rather, the labels 10 are configured such thatthe adhesive 24 is already the outer layer of the label constructionprior to application to an article 26, and so the adhesive 24 ispre-exposed and ready to contact an article 26—thereby increasing theease of application to an article 26.

The configuration of the layers in these embodiments of the presentlabels (e.g., those shown in FIGS. 2 and 2A) also results in the inkbeing beneath the printable layer 20 (and thus protected by theprintable layer 20) once the transfer portion 18 is transferred to anarticle 26. This results in the ink layer 22 (the indicia, graphics,design, text, information, etc.) being protected from damage once thelabel 10 is transferred to an article 26. This protection is achievedwithout having to add any additional protective lacquer layers (as isdone sometimes with prior art pressure sensitive labels). Theconfiguration that allows the printable layer 20 to protect the inklayer 22 following transfer also increases the number of materials thatmay be used in the ink layer 22—such as being able to use easily damagedmaterials, such as metallic inks.

The inks used in the ink layer 22 are used to create the various indicia(e.g., text, graphics, etc.) of the label. The indicia may be printedusing any printing process including, but not limited to, offsetprinting, flexographic printing, rotogravure printing, letterpressprinting, digital printing, ink jet printing, and screen printing.Further, the incorporation of standard printing effects such ascombination printing (the use of gravure printing in combination withflexographic printing in a single press), the use of cold-foil andhot-foil decoration, and pattern embossing, for example, arecontemplated by the invention described herein.

In one embodiment, the ink layer 22 may include UV-curable inks. In oneparticular embodiment, the UV-curable ink may include a blend of atleast polyfunctional components and photoinitiators. In particular, thepolyfunctional components may be polyfunctional acrylates. In oneembodiment, the UV-curable ink may include polyfunctional acrylates inan amount of greater than 30% based on the total resin weight. Morespecifically, one embodiment of a UV-curable ink may includepolyfunctional acrylates in an amount of 65-95 wt %, and aphotoinitiator blend in an amount of 1-20 wt %. An example of such anink is FP-500 UV process red ink, commercially available from Gotham InkCorporation of Marlboro, Massachusetts. Another such ink is commerciallyavailable from INX International Ink Co., of Schaumberg, Illinois, whichuses only polyfunctional components in its ink formulations (and thusdoes not include any monofunctional components) and is offered under thetrade name INXFIex2000 UV HTL. Another ink that can be used is an“ITX-Free” ink commercially available from INX International Ink Co., ofSchaumberg, Illinois.

Yet another embodiment of an ink that may be used is one includingpolyester acrylate, glycerol propoxy triacrylate [e.g.,poly(oxy(methyl-1,2,-ethanediyl)), alpha, alpha′,alpha″-1,2,3-propanetriyltris(omega-((1-oxo-2-propenyl)oxy)-; such asthat under CAS number 52408-84-1], hydroxycyclohexyl phenyl ketone (CASnumber 947-19-3) and acrylic acid—monoester with propane-1,2-diol (CASnumber 25584-83-2). In one specific embodiment of this ink, thepolyester acrylate may be present in an amount of about 1 wt % to about5 wt %, the glycerol propoxy triacrylate may be present in an amount ofabout 1 wt % to about 5 wt %, the hydroxycyclohexyl phenyl ketone may bepresent in an amount of about 0.5 wt % to about 1.5 wt %, and theacrylic acid, monoester with propane-1,2-diol may be present in anamount of about 0.1 wt % to about 1 wt %. The ink may have a flashpointhigher than about 93.3° C., a boiling/condensation point of about 100°C., a density of about 1049 g/l (about 8.7539 lbs/gal), and a viscosity[kinematic (room temperature)] of greater than about 2.2 cm²/s (greaterthan about 220 cSt). The VOC content of such an ink may be about 0.5% byweight. One such ink is a UV LED curing flexo ink commercially availablefrom Flint Group Narrow Web of Plymouth, Minnesota, under the trade nameEkocure FTM.

In another embodiment, the ink may be a solvent based ink, and mayinclude ethanol, propylene glycol methyl ether, propyl acetate,isopropanol, and aluminum flake. In one specific embodiment, the solventbased ink may include about 25 wt % to about 35 wt % ethanol, about 20wt % to about 25 wt % propylene glycol methyl ether, about 15 wt % toabout 20 wt % propyl acetate, about 15 wt % to about 20 wt %isopropanol, and about 3 wt % to about 5 wt % aluminum flake. Such anink may have a density of about 0.888 g/cm³, a flashpoint estimated tobe greater than about 23° C., and a boiling point of about 78.5° C. toabout 119.9° C. One such ink is commercially available from INXInternational Ink Co., of Schaumberg, Illinois, under the name “PlatinumPlus F124 Metallic,” and product code 1489010.

Other inks that may be used include digital inks, such as thosecommercially available from Indigo Ink of Columbia, Md. However, one ofordinary skill in the art will recognize that the above-described inksare not the only inks that can be used.

The various embodiments of the pressure sensitive label 10 (such asthose illustrated in FIGS. 2 and 2A) also include a pressure sensitiveadhesive 24. In various embodiments of the present invention, theadhesive chemistry used for the pressure sensitive adhesive 24 caninclude any formulation capable of being applied in a patternduplicating or similar to the contour, size, and shape of the printablelayer 20 as applied to the carrier 14.

As is generally known, pressure sensitive adhesives are adhesives whichform a bond when pressure is applied to marry the adhesive with theadherend. No solvent, water, or heat is needed to activate the adhesivein such instances. As the name indicates, the degree of bond isinfluenced by the amount of pressure which is used to apply the adhesiveto the surface. Further, pressure-sensitive adhesives are manufacturedwith either a liquid carrier or in 100% solid form. Articles such aslabels are made from liquid pressure sensitive adhesives by coating theadhesive on a support and evaporating the organic solvent or watercarrier, usually in a hot air dryer. The dry adhesive may be furtherheated to initiate a cross-linking reaction and increase molecularweight. 100% solid pressure sensitive adhesives may be low viscositypolymers that are coated and then reacted with radiation to increasemolecular weight and form the adhesive (a radiation cured pressuresensitive adhesive); or they may be high-viscosity materials that areheated to reduce viscosity enough to allow coating, and then cooled totheir final form (a hot melt pressure sensitive adhesive).

The pressure sensitive adhesive used may be consistent with typicalgravure printing, but modified to allow printing with flexographictechniques. A formulation for such a solvent adhesive may be UV curable.One particular adhesive in one specific embodiment of the presentinvention may be a high tack pressure sensitive adhesive adaptable forflexographic printing and having a viscosity of 1500-2000 cPs. Such anadhesive may include about 37.5 wt % to about 80 wt % acrylate, andabout 2.5 wt % to about 10 wt % of a photoinitiator (along withadditional materials making the remainder of the formulation). Theadhesive provided under this formulation may have a flash point of about94° C., and a specific gravity at 20° C. of about 1.06 g/cm³ (about 8.85lbs/gal). One such adhesive is commercially available from CraigAdhesives & Coatings of Newark, N.J. under the product name Craigbond1029BTJ UV High Tack PSA.

Another such adhesive in one specific embodiment of the presentinvention may have a formula including at least nonylphenol ethoxylatedacrylate (CAS number 50974-47-5), and ethoxyethoxy ethyl acrylate (CASnumber 7328-17-8), among other materials. The adhesive may also include2-hydroxy-2-methyl-1-phenyl-1-propanone. One such adhesive iscommercially available from Craig Adhesives & Coatings of Newark, N.J.under the product name Craigcote 1029J.

Another adhesive that may be used in various embodiments of the presentinvention includes a self-crosslinking acrylic polymer that cures uponsolvent removal. Such an adhesive may be about 53% to about 56%non-volatiles with a Brookfield viscosity at 77° F. of about 3500 toabout 6000. The solvent of the adhesive may be ethyl acetate/heptaneswith a solvent ratio of 83/17. The adhesive may have a density of about7.7 to about 8.1 lbs/gal (about 0.92 to about 0.98 gm/cm³), and a flashpoint of less than about 20° F. An example of such an adhesive iscommercially available from Ashland Performance Materials of Dublin,Ohio under the tradename AROSET™ PS-6416.

Yet another adhesive that may be used in various embodiments of thepresent invention includes a hot melt pressure sensitive adhesive. Suchan adhesive is 100% solids with a viscosity of about 66,500 at 300° F.,a Mettler softening point of about 250° F., and a density of about 7.8lbs/gal. Such an adhesive may also include a piperylene copolymer and amodified terpene resin. In one specific embodiment, this adhesives mayinclude about 10% to about 30% piperylene copolymer and about 10% toabout 30% modified terpene resin. The adhesive may have a boiling pointof greater than about 260° C., a melting point of about 110° C., aspecific gravity of about 0.98, and a flash point of greater than about260° C. (by the Cleveland open cup method). An example of such anadhesive is commercially available from Henkel Corporation of RockyHill, Conn. under the trade name Technomelt® and product numberTechnomelt® PS 9197.

However, one of ordinary skill in the art will recognize that these arenot the only adhesives that can be used. For example, other UV-curableadhesives may be used. Ultraviolet (UV) light curing adhesives, alsoknown as light curing materials (LCM), have become popular within themanufacturing sector due to their rapid curing time and strong bondstrength. Light curing adhesives can cure in as little as a second andmany formulations can bond dissimilar substrates (materials) andwithstand harsh temperatures. Unlike traditional adhesives, UV lightcuring adhesives not only bond materials together but they can also beused to seal and coat products.

In this embodiment of the pressure sensitive labels 10, the adhesivelayer 24 is UV cured following the printing step. As such, the label 10can be wound in roll form without blocking (due to tackiness). Duringthe decoration step, heat (or heat and pressure) is applied and theadhesive becomes soft, fluid, and tacky just prior to application atwhich point the label 10 bonds to the substrate.

One such UV-curable heat activated adhesive is HS30 and is commerciallyavailable from Actega Radcure Inc. of Wayne, N.J. Per the MSDS, HS30 isused as a UV/EB curable adhesive, primer, coating. Another such heatactivated UV cured adhesive is FP-500 NUV85 from Gotham Ink Corporationof Marlboro, Mass. FP-500 NUV85 is a proprietary mixture of materials.However, those of ordinary skill in the art will recognize that theseare not the only UV-curable adhesives that can be used, and that otherUV-curable adhesives providing similar characteristics can be used.

In another aspect, the pressure sensitive label 10 as shown in theembodiments of FIGS. 2 and 2A may further include a release layer 27positioned such that the carrier layer 14 is between the printable layer20 and the release layer 27. In other words, the release layer 27 is noton the side of the carrier 14 adjacent to the transfer portion 18 of thelabel 10, but rather is on the underside of the carrier 14. This releaselayer 27 allows the web of labels 10 to be wound on a roll, for example,while preventing blocking (i.e., the problem of the adhesive on thelabels adhering to the underside of the carrier as the web of labels iswound on the roll). Thus, the presence and positioning of this releaselayer 27 allows the web of labels to be wound into a roll after printingof the labels 10. In particular, the bond of the pattern appliedprintable layer 20 is greater to the top surface of the continuous webof the carrier layer 14 than it is to the release layer 27 on the bottomside of the carrier layer 14. Thus, when the roll is unwound, the label10 is positioned adhesive side up to allow ease of application toarticles 26 being labeled.

One particular release formulation for a release layer in one specificembodiment of the present invention may include a UV curable releasematerial, and such a material may—in one embodiment—be a cationicrelease coating. Such a release formulation may include dimethylsiloxanes and silicones (CAS number 67762-95-2). An example of such amaterial is commercially available from Craig Adhesives and Coatings, ofNewark, N.J. under the trade name Craigcoat UV9300 and product codeuv9300. In an embodiment of the present invention, the release materialdescribed above may include a photocatalyst material used in conjunctiontherewith. Such a photocatalyst material may include—in oneembodiment—2-isopropylthioxathone, C12 and C14 alkylglycidyl ethers,bis(4-dodecylphenyl)iodonium hexafluoroantimonate, and linear alkylatedodecylbenzene. More specifically, a certain embodiment may includeabout 1% to about 5% 2-isopropylthioxathone, about 30% to about 60% C12and C14 alkylglycidyl ethers, about 30% to about 60%bis(4-dodecylphenyl)iodonium hexafluoroantimonate, and about 5% to about10% linear alkylate dodecylbenzene. An example of such a photocatalystmaterial is commercially available from Craig Adhesives and Coatings, ofNewark, N.J., under the trade name UV9390C.

As described above, and referring now to FIGS. 3 and 3A, another aspectof the present invention provides a pressure sensitive label comprising:(a) a support portion including at least a carrier layer; and (b) atransfer portion including at least a printable layer in confrontingrelationship with the carrier layer. In a label of this aspect, an inklayer may be present between the printable layer and the carrier layer.Depending on the nature of the ink layer, at least a portion or portionsof the printable layer may contact the carrier layer (i.e., in any areaswhere ink or inks of the ink layer are not present). In general, thetransfer portion may overlie the support portion for transfer of thetransfer portion from the support portion to an article upon applicationof pressure to the transfer portion while the transfer portion is incontact with the article. In one embodiment, the carrier layer does notinclude any release layer on the side of the carrier layer facing theprintable layer. This eliminates a layer of the labels of the prior art,thus reducing the cost of the label. In this configuration, the pressuresensitive labels of this aspect include the ink layer most proximal tothe carrier, and the adhesive layer most distal to the carrier. Due tothis configuration, the transfer portion (e.g., ink layer, printablelayer, adhesive layer) of the pressure sensitive labels described inthis aspect do not have to be peeled away from the carrier to expose theadhesive for adherence to an article. Rather, the labels are configuredsuch that the adhesive is already the outer layer of the labelconstruction prior to application to an article, and so the adhesive ispre-exposed and ready to contact an article—thereby increasing the easeof application to an article.

Referring now to FIG. 3, a particular embodiment of such a pressuresensitive label 10 is shown. As can be seen in FIG. 3, the pressuresensitive label 10 of the illustrated embodiment is a multilayeredconstruction, with each layer having its own function. Other embodimentsare also of a multilayered construction. The embodiment of label shownin FIG. 3 does include the general support portion 12 and transferportion 18 described above. The support portion 12 of each embodimentincludes a carrier layer 14, which may have a release coating 16 (e.g.,a wax or silicone coating) on one side thereof (which can be seen in theembodiment shown in FIG. 3A). In an alternate embodiment, the carrier 14may have no release coating (on the carrier facing the ink layer—see theembodiment of FIG. 3), but may be otherwise treated, such as by a coronatreatment. In still other embodiments, the carrier 14 may be untreatedand have no release coating. The transfer portion 18 of each of theembodiments is positioned adjacent to, and in confronting relationshipwith, the carrier 14 prior to transfer therefrom. The transfer portion18 of the embodiments includes at least (1) a printable layer 20 inconfronting relationship with the carrier 14. Such a confrontingrelationship does not require contact between the two layers (althoughcontact is possible). The layers merely need be proximal and adjacentone another. The transfer portion 18 may also include an ink layer 22,and an adhesive layer 24. The ink layer 22 may be positioned such thatit is between the carrier layer 14 and the printable layer 20. And, theadhesive layer 24 may be positioned such that the printable layer 22 isbetween the ink layer 22 and the adhesive layer 24. Additional layersmay be included within the transfer portion 18.

Referring still to FIG. 3, the illustrated embodiment includes a carrierlayer 14, an ink layer 22, a printable layer 20, a pressure sensitiveadhesive layer 24, and a backside release layer 27. As can be seen fromFIG. 3, the release layer 27 is positioned such that the carrier layer14 is between the ink layer 22 and the release layer 27. As will bedescribed in further detail below (in a more detailed discussion of thevarious layers of the labels 10), the backside release layer 27 preventsblocking when the web of labels is wound on a roll, for example.

As described above, the various pressure sensitive label embodiments inaccordance with principles of the present invention include a carrierlayer 14. The carrier layer 14 as used in certain embodiments (and inthe illustrated embodiment of FIG. 3) is of a material that allows thetransfer portion 18 of the label 10 to separate from the carrier layer14 without the need for a separate release layer (such as release layersin the prior art). This allows for the reduction in materials and costused in the present pressure sensitive labels. And so, in embodiments ofthe present invention, the carrier layer 14 is of, or includes, amaterial having a surface tension that allows the printable layer 20 toreleasably bond thereto. And, in more specific embodiments of thepresent invention, the surface of the carrier layer 14 that contacts theprintable layer 20 may have a dyne level below about 32.

In other embodiments (such as the illustrated embodiment of FIG. 3A),the carrier layer may have a coating 16 applied to the surface that willconfront the ink layer 22 of the label 10. Thus, the carrier layer 14has two surfaces: (1) a top surface 29, which has a surface tension lowenough to allow the ink layer 22 to releasably bond to it (which can beaccomplished, as described above, with various treatments of the topsurface—such as with silicones and/or waxes in the embodiment of FIG.3A); and (2) a bottom surface 31, which is treated (as will be describedin greater detail below) to prevent adhesives 24 from adhering toit—thereby allowing the finished web of labels to be wound into a roll(and subsequently unwound during the label application process) withoutdamaging the labels by having the labels adhere to one another and tothe web (i.e., blocking).

The printable layer 20 (in the embodiments of FIGS. 3 and 3A) will bepositioned behind the ink or inks of the ink layer 22 once the label isapplied to an article. The printable layer 20 is the filmic layer thatprovides some mass and bulk to the label. Further, the printable labelmay include pigments in its formulation in or to provide a degree ofopaqueness (i.e., a background) to any label information, text,graphics, etc provided by the ink layer. This opaqueness may be providedin any color desired. Alternatively, the printable layer may be clear.The use of pigments to provide a degree of background coloration is wellknown to those of ordinary skill in the art.

The layers (carrier 14, ink layer 22, printable layer 20, adhesive layer24, backside release layer 27, etc.) of the embodiments of FIGS. 3 and3A of the present invention may include various materials, includingthose described above with respect to the embodiments of FIGS. 2 and 2A.

As described above, various embodiments of the label may include otherlayers. One such layer may be a protective layer, which may be used toprotect the ink layer from abrasion following transfer of a label to anarticle (such as the version shown in FIGS. 3 and 3A, where the inklayer would be the outer exposed layer of the label following transfer.Such an embodiment including a protective layer 33 is shown in FIGS. 4and 4A. The transfer portion 18 of this embodiment includes at least (1)a printable layer 20 in confronting relationship with the carrier 14.Such a confronting relationship does not require contact between the twolayers (although contact is possible). The layers merely need beproximal and adjacent one another. The transfer portion 18 may alsoinclude an ink layer 22, and an adhesive layer 24. The ink layer 22 maybe positioned such that it is between the protective layer 33 and theprintable layer 20. And, the adhesive layer 24 may be positioned suchthat the printable layer 22 is between the ink layer 22 and the adhesivelayer 24. And, the protective layer 33 may be positioned such that it isbetween the carrier 14 and the ink layer 22. (The embodiment shown inFIG. 4A is of similar construction, though it includes a separaterelease layer 16 on one side of the carrier 14.)

Referring still to FIG. 4, the illustrated embodiment includes a carrierlayer 14, a protective layer 33, an ink layer 22, a printable layer 20,a pressure sensitive adhesive layer 24, and a backside release layer 27.As can be seen from FIG. 3, the release layer 27 is positioned such thatthe carrier layer 14 is between the protective layer 33 and the releaselayer 27. The backside release layer 27 prevents blocking when the webof labels is wound on a roll, for example (as has been described abovewith respect to the embodiments of FIGS. 2 and 3).

The protective layer 33 may be of various kinds including, but notlimited to UV-cured or UV-curable overprint varnishes. However, theprotective layer may be of other types (for example solvent gravure HTLprotective layers).

In one example, then, the protective layer 33 may be a coating of aUV-curable chemistry in which the formula has been modified withadditives that will increase the scuff resistance and or chemicalresistance. Such a coating may have the properties of high gloss,chemical resistance, good UV reactivity, free of benzophenone andbisphenol A, and non-yellowing. One particular coating for a protectivelayer may have a film weight of 0.40-0.70 lbs/1000 sqft, using a 180-250lpi, 6-9 billion cubic microns (bcm) per square inch anilox roll; aviscosity of 160 centipoise (cps) using a Brookfield RV, #3 spindle, 100revolutions per minute (rpm) @ 77° F. (25° C.); may cure at 150-250 feetper minute (fpm) per 400 watts per inch (wpi) lamp; may appear as atranslucent liquid; may have a gloss of >90 @ 60° angle (over blackportion of Leneta N2A-3); may have a measured static CoF<0.30 and akinetic CoF between 0.15-0.21, using a 200 gram sled; and may have asolvent resistance of >50 methylethyl ketone (MEK) double rubs (those ofordinary skill in the art will recognize that properties such as glossCoF, and solvent resistance will depend on coating film thickness,degree of cure and substrate type). One specific example of such acoating to be used for a protective layer would be SunCure® HG (HighGloss) TL 4098 coating (commercially available under product numberRCYFV0484098 from Sun Chemical, of Parsippany, N.J.). Such a coating maybe applied with flexo, tower coater, or roller coater.

While the above embodiments (of FIGS. 4 and 4A) describe a protectivelayer 33 that is separate from the ink layer, alternate embodiments mayinclude a protective layer that is combined with providing the graphicsof the ink layer. This may be achieved by pigmenting the protectivelayer to be the color or colors of ink that is desired (and configuredinto the various desired graphics, text, etc. of the label.

As described above, another aspect of the present invention may includea method or methods for making a pressure sensitive label. And stillanother aspect of the present invention may include a method or methodsfor applying a pressure sensitive label to an article. Referring now toFIG. 5, the pressure sensitive label 10 of embodiments such as thatshown in FIG. 2 may be prepared as follows: The printable layer 20 maybe laid down on a carrier layer 14 by a first roller/cylinder 34 (forexample), followed by the ink layer 22 being laid down on the printablelayer 20 by a second roller/cylinder 36, and then the adhesive layer 24being laid down on the ink layer 22 by a third roller/cylinder 38,thereby forming a label 10 with these separate and distinct layers.During the process of laying down the printable layer 20, ink layer 22,and adhesive layer 24, a release layer 27 may also be applied to theopposite side of the carrier layer from the transfer portion of thelabel by a fourth roller/cylinder 40. In the embodiments where one ormore of these layers (printable, ink, adhesive, release) is UV-curable,they may be exposed to UV radiation provided by ultraviolet light, whichcures the various UV-curable layers. This UV-curing may be done as eachseparate UV-curable layer is laid down, or it may occur after allUV-curable layers have been laid down. (Further, although FIG. 5 shows,and is described as, putting down a printable layer followed by an inklayer, those skilled in the art will recognize that for embodiments ofthe label having a different ordering of layers—such as that shown inFIGS. 3 and 3A—the layers may be put down in a different order thanshown in FIG. 5, e.g., ink layer put down followed by printable layer.)

Further, any UV-curable components may be applied using flexographicprinting techniques. UV components do not present the problem of“swelling” when used in flexographic printing (unlike certain typicalrotogravure solvent components). Flexographic printing is a process thatis well known to those of ordinary skill in the art. In general, in theflexographic process (used for the UV cured ink), a flexible reliefplate (not shown) includes image areas raised above the non-image areas.A component, such as ink, is transferred from an ink roll (not shown),which is partially submerged in an ink tank to a second roll (not shown)whose texture holds a specific amount of ink. A doctor blade (not shown)then removes excess ink from the second roll before inking the flexiblerelief plate. The substrate is then positioned between the plate and animpression cylinder (not shown) to transfer the image. While the plateis described as having “image areas,” the “image” of those areas may bedesigned as to provide a floodcoating of the protective lacquer layeronto the substrate.

By using flexographic printing techniques for various layers of thelabel 10, this aspect of the present invention results in cost savingsover that of previously manufactured pressure sensitive labels 10, (orlabels 10 including a UV-curable layer), using rotogravure printingtechniques. This is because rotogravure printing techniques areexpensive, especially as compared to printing techniques such asflexographic printing. By eliminating gravure printing for the layers ofthe pressure sensitive label 10 (especially those that include the mostcomplicated design—i.e., the ink layer 22), great cost savings may berealized due to the need not to have to provide multiple and differentetched gravure cylinders for different production runs.

However, the layers of the labels 10 are not limited to flexographictechniques, and may be applied using other techniques, including gravureprinting techniques. In rotogravure techniques (which are also wellknown to those of ordinary skill in the art), the printing plate (notshown) is in cylinder form, and includes wells that are etched orengraved to differing depths and/or sizes to provide the image orimages. The component such as the protective lacquer or adhesive isapplied directly to the cylinder by rotating in a bath (not shown) whereeach cell of the image is flooded with the lacquer or adhesive. A doctorblade (not shown) wipes away the excess lacquer or adhesive, andcapillary action of the substrate and pressure from impression rollers(not shown) draw the lacquer or adhesive out of the wells and transferit to the substrate.

Thus, the apparatus (not shown) for a gravure printed layer includes agravure printing unit (not shown) for a rotary press, with a gravuresleeve (not shown) supplied with lacquer or adhesive from a gravure tray(not shown) and an impression roller (not shown), which lies inconfronting relationship to the gravure sleeve, to form a roller gap(not shown) therebetween. When the rotary press is running, a carrier,such as a sheet material, that is to be printed is passed through theroller gap, taking up lacquer or adhesive from the peripheral surface ofthe gravure sleeve. At the same time, the gravure sleeve rotates in aspecified direction opposite to that of the impression roller and itsrotational movement is composed of a leading, rotating sector from theprinting unit to the roller gap and a trailing rotating sector from theroller gap to the printing unit. Apparatus and techniques for bothrotogravure and flexographic printing are common and are very well knownto those of ordinary skill in the art.

Further, as has been mentioned above, certain layers of the label (e.g.,printable layer 20, ink layer 22, and adhesive layer 24), may be laiddown, or printed, in a particular pattern corresponding to the size,shape, and/or contour of the desired end label image. This also resultsin solving a problem of the prior art (which led to too much materialbeing used, and thus, increased cost to labels). Because the ink designis printed only on a portion of the base construction that (in priorart) is purchased from a third party, this requires that the face stockonto which the ink is printed be a film that spans the entirety of thecarrier (to be die cut later on). It also requires that the adhesive(which is part of the base construction in the prior art) be floodcoated onto the carrier (since this is done before sale of the baseconstruction). In other words, since the carrier suppliers do not knowin advance what ink designs will be applied by the label-maker, theyflood-coat the entire carrier with adhesive, and cover the entirety ofthe carrier with face stock, to allow for any size, shape,configuration, and registration of ink design. The use of such a largeamount of face stock and flood-coated adhesive results in a large amountof unused, and thus excess, adhesive, as well as an excess amount offace stock that must be die cut and discarded. The use of this excessiveamount of adhesive and face stock results in increased costs to theprior art labels, because the excess amount of face stock and adhesiveresults in increased cost of the carrier, and thus increased cost oflabel preparation and of the labels themselves.

However, the design of the present pressure sensitive label 10 allowsfor printing of a printable layer 20 to be laid down in a pattern, aswell as a patterned ink layer 22 and an adhesive 24. This is due in partto the construction of the label in somewhat reverse order to previouspressure sensitive labels. In other words, the prior art labels had anadhesive disposed on the release of a carrier, with the face stock ontop of the adhesive, and the ink on top of the face stock. In the labelof the present application, the printable layer may be applied at thesite of labeling with the ink on top of the printable layer and theadhesive on top of that. Since this occurs at the site of labeling, theentity providing and creating the label will know at the time ofprinting what the design of the label will be. And so, rather thanproviding a face stock of the same area as the carrier, the presentinvention does not use a face stock. Rather, the typical face stock ofpressure sensitive labels of the prior art is eliminated, and instead aprintable layer (such as an imprintable varnish) may be placed down onthe carrier. This allows one to print the printable layer in the shapeof the final label design—which allows one to create a label without theneed for die cutting any extra face stock. In one embodiment, theprintable layer may be applied using a 30 bcm anilox roller.

In the same manner, this allows one to also print the adhesive onto theink design in the shape of the ink design (i.e., having a same orsimilar outer contour to the ink design) in order to avoid the waste ofexcess adhesive that occurs via floodcoating in the prior art. In oneembodiment, the ink layer may be applied using an 8 bcm anilox roller.In one embodiment, the adhesive layer may be applied using a 4.5 bcmanilox roller. In another embodiment, the adhesive layer may be appliedusing an 8 bcm anilox roller.

For example, then, another aspect of the present invention provides aprocess for applying a printable layer 20, ink layer 22, and/or anadhesive layer 24 onto a carrier, wherein the printable layer 20, inklayer 22, and/or adhesive layer 24 covers less than substantially theentire surface of a first side of the carrier. Thus, the printable layer20, ink layer 22, and/or adhesive layer 24 can be applied in a patternedform and/or can be applied to match any size, shape, configuration, orregistration desired for a label. More specifically, this process mayinclude contacting the materials for the printable layer 20, ink layer22, and/or adhesive layer 24 with a surface having at least one etchedregion thereon, and confronting the carrier 14 (for example) with thesurface such that at least a portion of the printable layer 20 transfersfrom the surface to the carrier 14. The printable layer that transfersmay particularly be received by and transferred from the etched regionof the surface. Thus, the process may include (a) softening a materialfor the printable layer 20 (such as by melting the formulation), (b)contacting the softened printable layer and/or adhesive formulation witha gravure sleeve having at least one etched portion wherein theformulation is adsorbed onto the surface of the gravure sleeve, (c)removing excess printable layer from the surface of the gravure sleeveso the printable layer formulation is adsorbed only to the etchedportion of the gravure sleeve, and (d) contacting the gravure sleevewith the carrier to deposit the printable layer and/or adhesiveformulation onto the carrier, thereby forming a printable layer 20 upona portion of the carrier 14. An ink layer 22 can then be printed ontothe printable layer, and an adhesive layer can then be printed onto theink layer to form a label having a support portion and a transferportion. The transfer portion of the label may be subsequentlytransferred onto an article.

In use, and referring now to FIGS. 7 and 8, the label 10 in accordancewith principles of the present invention is applied to an article 26 asfollows. In the illustrated embodiment, the labels 10 are carried on aweb that has been wound into a roll 42. The transfer portion 18 of thelabels 10 are releasable from the support portion 12 (e.g., carrier 14)and the web progresses from a feed reel 44 to a take-up roll 46. Afterbeing unwound from the rotating feed reel 44, the web of labelsgenerally will pass proximal to the articles 26 being labeled. It willbe recognized by those of skill in the art that the various rolls listedabove are merely exemplary, and are not necessary to the principles ofthe present invention. Upon reaching proximity to the article 26 (see 48of FIG. 7), contact occurs between the adhesive layer 24 of the transferportion 18 of the label 10 and a surface of the article 26. At thispoint, pressure may be applied to adhere the adhesive layer 24 of thelabel 10 to the surface of the article (by methods and apparatusgenerally known to those of ordinary skill in the art). This pressurefacilitate adherence of the transfer portion of the label 10 to thearticle 26. After the transfer portion 18 has been applied to an article26, the bond between the adhesive layer 24 and article is stronger thatthe releasable bond between the printable layer 20 and carrier 14 (orprintable layer 20 and release composition 16—or ink layer 22 andcarrier 14). This causes the transfer portion 18 to peel away from thesupport portion 12 as the web of labels and articles continue to move.The now empty carrier web (i.e., support portion 12) may progress to atake-up reel 46, where it may be recycled (or discarded). It will berecognized by those skilled in the art that the particular number, type,and configuration of components described above are merely illustrative.And after the web has moved past the labeling point, the article 26 (asseen in FIG. 8) now includes the transfer portion 18 of the labeladhered thereto.

The application of the label described in this application may occurwith the label being rolled onto the article in the same or similar waya heat transfer label would be, which eliminates the opportunity forwrinkles and blisters to occur, thereby reducing and/or eliminating oneof the problems with pressure sensitive labels of the prior art.

The embodiments of the present invention recited herein are intended tobe merely exemplary and those skilled in the art will be able to makenumerous variations and modifications to it without departing from thespirit of the present invention. For example, the particular types ofmaterials used in the adhesive, ink, and protective lacquer layers maybe selected to optimize performance of the label, interlayer adhesion,article adhesion, and/or mechanical and chemical resistance suitable forthe intended use of the article. Further, the above description mayinclude disclosures of specific materials to use in each individuallayers of a label (i.e., a specific ink may be described and so thespecification discloses the use of that specific ink, with any carrier,printable layer, and adhesive). However, those descriptions will also beunderstood by those of skill in the art to include embodiments includingthe specific material described in each layer of the label (i.e. aspecific ink, specific, carrier, specific, printable layer, and specificadhesive described at various locations of the specification will beunderstood to include a specific embodiment including each of thosespecific materials). Notwithstanding the above, certain variations andmodifications, while producing less than optimal results, may stillproduce satisfactory results. All such variations and modifications areintended to be within the scope of the present invention as defined bythe claims appended hereto.

The invention claimed is:
 1. A pressure sensitive label comprising: (a)a support portion, said support portion including a carrier layer; and(b) a transfer portion over said support portion for transfer of thetransfer portion from the support portion to an article upon applicationof pressure to the transfer portion while the transfer portion is incontact with the article, said transfer portion including (1) aprintable layer in confronting relationship with the carrier layer,wherein the printable layer includes about 30 wt % to about 50 wt % of atriacrylate ester monomer, about 10 wt % to about 12.5 wt % of adiacrylate ester monomer, about 10 wt % to about 12.5 wt % of anaromatic urethane acrylate, about 10 wt % to about 12.5 wt % of adifunctional acrylate, about 5 wt % to about 7 wt % of an acrylateoligomer, about 3 wt % to about 5 wt % of triethanolamine, and about 1wt % to about 2 wt % of 4-phenylbenzophenone, and (2) an ink layerdisposed between the printable layer and the carrier layer.
 2. Thepressure sensitive label of claim 1, further comprising an adhesivelayer positioned such that said printable layer is between said inklayer and said adhesive layer.
 3. The pressure sensitive label of claim1, further comprising a release layer positioned such that said carrierlayer is between said ink layer and said release layer.
 4. The pressuresensitive label of claim 1, wherein the carrier layer has a surfacetension that allows the ink layer to releasably bond thereto.
 5. Thepressure sensitive label of claim 4, wherein the surface of the carrierlayer that contacts the ink layer has a dyne level below about
 32. 6.The pressure sensitive label of claim 4, wherein the carrier layercomprises polypropylene.
 7. The pressure sensitive label of claim 1,wherein the carrier layer is chosen from plastic film, foil, parchment,and paper.
 8. The pressure sensitive label of claim 1, wherein the inklayer comprises about 25 wt % to about 35 wt % ethanol, about 20 wt % toabout 25 wt % propylene glycol methyl ether, about 15 wt % to about 20wt % propyl acetate, about 15 wt % to about 20 wt % isopropanol, andabout 3 wt % to about 5 wt % aluminum flake.
 9. The pressure sensitivelabel of claim 2, wherein the adhesive layer comprises about 37.5 wt %to about 80 wt % acrylate, and about 2.5 wt % to about 10 wt % of aphotoinitiator.
 10. The pressure sensitive label of claim 3, wherein therelease layer comprises dimethyl siloxane and silicone.
 11. The pressuresensitive label of claim 1, wherein said label does not include anyrelease layer between said carrier layer and said ink layer.